Carpet backing precoats, laminate coats, and foam coats prepared from polyurethane formulations including fly ash

ABSTRACT

The present invention is a polyurethane carpet backing prepared from a polyurethane-forming composition wherein fly ash is included as a filler material. High loadings of fly ash can be obtained without detriment to the process for preparing a polyurethane carpet backing, or adverse effect to the physical properties of the carpet backing.

This application is a continuation-in-part application of U.S. patentapplication Ser. No. 08/703,158, filed Aug. 28, 1996, now U.S. Pat. No.6,096,401.

BACKGROUND OF THE INVENTION

The present invention relates to polyurethane-backed articles. Thepresent invention particularly relates to polyurethane-backed articlesand to a process and composition used in making same.

Articles having attached polyurethane foam layers are well known. Forexample, carpets and other substrates having attached polyurethane foamlayers as backing are described in U.S. Pat. Nos.: 3,755,212; 3,821,130;3,862,879; 4,022,941; 4,171,395; 4,278,482; 4,286,003; 4,296,159;4,405,393; 4,483,894; 4,512,831; 4,515,646; 4,595,436; 4,611,044;4,657,790; 4,696,849; 4,853,054; 4,853,280 and, 5,104,693. Typically afiller material is used to prepare a polyurethane formulation for carpetbacking. The filler can replace some of the polymer required to preparea polyurethane backed article, while maintaining bulk in the article.This can lower the cost of production of the article, since materialsused as fillers are typically less expensive than the polymer materialthat is being replaced.

In selecting a filler for a particular application, the effect that thefiller can have on the process—and on the physical properties of thearticle—should be considered. For example, in a process for preparingpolyurethane backed carpets, a filler that is too alkaline can causepremature gellation. Conversely, a filler that is too acidic can causean unacceptable delay in the onset of gellation. Increasing the amountof conventional fillers used in preparing carpet backing, such ascalcium carbonate (CaCO₃) and aluminum trihydrate (ATH), can result inan undesirable viscosity increase in a polyurethane formulation.

While cost reduction can be an incentive for introducing as much filleras possible into a polyurethane formulation, it can be unacceptable toreduce the cost of production at the expense of the quality of thearticle produced. The amount of filler incorporated into a polyurethaneformulation can be limited by the adverse effects that the filler canhave on the properties of a polyurethane, such as flexibility,resiliency, and adhesion, for example.

Fly ash has been used as a filler material in systems such as cement andconcrete products, roadbases/subbases, and structural fills. See, forexample, U.S. Department of Transportation/Federal HighwayAdministration Report No. FHWA-SA-94-081 (August 1995). The ElectricPower Research Institute (EPRI), in EPRI Report CS-4765 (September 1986)(hereinafter CS-4765), reported that fly ash recovered from a directacid leaching process was added as a filler to polymerized nylon andpolypropylene.

It would be desirable to increase the loading of filler into apolyurethane formulation without detriment to the process of preparing apolyurethane carpet backing, or to the final physical properties of thefinal product. It would also be desirable to use fly ash as a fillermaterial in a reactive polymeric system without significant effect on apolymer forming reaction.

SUMMARY OF THE INVENTION

In one aspect, the present invention is a polyurethane-formingcomposition, useful for preparing a polyurethane precoat, polyurethanelaminate coat, or polyurethane foam coat comprising a polyol; a chainextender; a polyisocyanate; a catalyst; a surfactant; a filler wettingagent; and a filler, wherein the filler includes fly ash; and optionallyincluding a surfactant and a blowing agent.

In another aspect, the present invention is a backed carpet having apolyurethane backing that includes at least one coat of polyurethanethat is prepared from a polyurethane-forming composition comprising apolyol; a chain extender; a polyisocyanate; a catalyst; a filler wettingagent; a filler, wherein the filler includes fly ash; and optionallyincluding a surfactant and a blowing agent.

In still another aspect, the present invention is a process forpreparing a carpet having a polyurethane backing comprising the steps:(1) applying at least one layer of a polyurethane-forming composition toa carpet substrate, wherein the polyurethane-forming compositionincludes fly ash; and (2) curing the polyurethane-forming composition toform a tack-free polyurethane backing. Applicant has developed a processfor preparing a polyurethane composition which incorporates fly ash as afiller material. The process of the present invention can result in animproved process, including increased flow of a polyurethane compositioninto the backstitch of a carpet, and increased pot life of apolyurethane composition. The use of fly ash as filler reduces pillingand fuzzing of the carpet face, improves flexibility of the carpetduring installation, and also reduces puddle gellation duringapplication of a polyurethane-forming composition. In addition, fly ashcan be included at a higher loading than conventional fillers, withoutdetriment to established process parameters or to the physicalproperties of a polyurethane carpet backing.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

The polyurethane-forming composition of the present invention comprisesa polyol as described herein, a chain extender, a polyisocyanate, acatalyst as described herein, a surfactant, a filler wetting agent, anda filler that includes fly ash. The composition of the present inventioncontains reactive components such as active hydrogen containingcompounds and compounds having isocyanate functionality.

Active hydrogen containing compounds are compounds having activehydrogen functionality, wherein at least one hydrogen atom is bonded toan electronegative atom such as sulfur, nitrogen, or oxygen. Activehydrogen containing compounds described herein can contain anycombination of hydroxyl , amino, and mercaptyl functionality—in additionto other active hydrogen groups—and can be reacted with isocyanategroups under conditions suitable for preparing a polyurethane carpetbacking. The average functionality of an active hydrogen containingcompound refers to the average number of active hydrogen groups percompound.

A polyol is an example of an active hydrogen containing compound, in thepresent invention. As used herein, the term “polyol” can refer to asingle polyol or to a mixture of two or more polyols. A polyol of thepresent invention can have an average equivalent weight of from about500 to about 5000, preferably from about 750 to about 2500, and morepreferably from about 750 to about 2000. The average equivalent weightof a compound can be determined by dividing the average molecular weightof the compound by the functionality of the compound. In the presentinvention, at least about 30 percent, preferably about 50 percent, andmore preferably about 60 percent of the hydroxyl functionality of apolyol is primary hydroxyl functionality. While a wide range ofmaterials can be used, polyether polyols are preferred based on theirperformance and wide availability. Polymers of propylene oxide which areat least partially end-capped with ethylene oxide are particularlypreferred.

Polyols of the present invention are prepared by known methods byreacting an alkylene oxide with a suitable polyhydric initiatorcompound. The alkylene oxide preferably has 2-8 carbon atoms. Forexample suitable alkylene oxides can be ethylene oxide, propylene oxide,1,2-butylene oxide, 2,3-butylene oxide, styrene oxide, epichlorohydrin,3-methyl-1,2-butylene oxide, like compounds and mixtures thereof, withpropylene oxide being the preferred oxide. The initiator compound can bea polyhydric compound such as water, ethylene glycol, propylene glycol,1,2-butane diol, 1,3-butane diol, glycerine, trimethylol propane,p,p′-isopropylidine diphenol, aniline, ammonia, ethylene diamine,aminoethylethanolamine, like compounds and mixtures thereof.

When a single polyol is used in the present invention, the polyol canhave an average functionality of from about 1.4 to about 3.0. Preferablythe average functionality of the polyol is from about 1.6 to about 2.8.A mixture of polyols can be used which includes at least a second polyolin addition to the first polyol. The second polyol can be described inthe same manner as the first polyol except that the second polyol canhave a functionality of at least about 2.05. Preferably, the secondpolyol has a functionality of from about 2.4 to about 3.0, morepreferably the functionality is from about 2. 5 to about 2.95. When apolyol mixture is used, the average functionality of the polyol mixturecan be from about 1.97 to about 2.5, preferably from about 1.98 to about2.4 and more preferably from about a 1.99 to about 2.3.

The present invention optionally includes a chain extender. A chainextender is typically a low equivalent weight active hydrogen containingcompound having about 2 active hydrogen groups per molecule. The activehydrogen groups can be hydroxyl, mercaptyl, or amino groups. If theactive hydrogen groups are amino groups then the amine is preferably asterically hindered amine. A sterically hindered amine is an amine thatis substituted with bulky groups that tend to inhibit the reactivity ofthe amine, for example alkyl groups having 2 or more carbons. An aminechain extender can also be blocked, encapsulated, or otherwise renderedless reactive. Preferred chain extenders include glycols and glycolethers such as: ethylene glycol; 1,4-butane diol; 1,6-hexamethyleneglycol; dipropylene glycol; tripropylene glycol; diethylene glycol;triethylene glycol; cyclohexanedimethanol; the diverse bisphenols; likecompounds and mixtures thereof. Suitable amine chain extenders include:methylene bis(o-chloroaniline); NaCl-blocked methylene dianiline;diethyltoluenediamine; like compounds, and mixtures thereof.

In preparing a polyurethane backing of the present invention, smallamounts of chain extender are advantageously used. Generally, from about5 to about 50 parts, preferably from about 5 to about 30 parts of thechain extender per 100 parts of polyol, by weight, are used. Morepreferably from about 5 to about 20 parts of chain extender per 100parts of polyol are used in the practice of the present invention.

The polyurethane-forming composition of the present invention alsoincludes a polyisocyanate. The average functionality of a polyisocyanateis the average number of isocyanate groups per molecule. Thepolyisocyanate used herein has an average functionality of from about1.9 to about 3.0. The polyisocyanate preferably has an averagefunctionality of about 1.95 to about 2.5, and more preferably from about1.95 to about 2.4. Most preferably, the polyisocyanate has an averagefunctionality of from about 2.0 to about 2.4.

The polyisocyanate can be aliphatic or aromatic. Aromaticpolyisocyanates suitable for use herein include: phenyl diisocyanate;2,4-toluene diisocyanate; 2,6-toluene diisocyanate; ditoluenediisocyanate; naphthalene 1,4-diisocyanate; 2,4′- and/or4,4′-diphenylmethane diisocyanate (MDI); polymethylenepolyphenylenepolyisocyanates (polymeric MDI); like compounds, andmixtures thereof. Suitable aliphatic polyisocyanates include: thehydrogenated derivatives of suitable aromatic polyisocyanates such as1,6-hexamethylene diisocyanate; isophorone diisocyanate; 1,4-cyclohexyldiisocyanate; like compounds and mixtures thereof. Prepolymers preparedby reacting a polyol or chain extender with a polyisocyanate aresuitable, as well.

The polyisocyanate can be used in an amount suitable to prepare apolyurethane-forming composition with an isocyanate index of from about85 to about 130. The isocyanate index can be calculated by multiplyingthe ratio of isocyanate equivalents to active hydrogen equivalents by100. The preferred isocyanate index is a variable that depends on theamount of water in the textile. Preferably the isocyanate index is inthe range of from about 85 to about 115 for a laminate coat, andpreferably from about 85 to about 110 for a foam coat.

A catalyst is used in the practice of the present invention. Suitablecatalysts include tertiary amines, and organometallic compounds, likecompounds and mixtures thereof. For example, suitable catalysts includedi-n-butyl tin bis(mercaptoacetic acid isooctyl ester), dimethyltindilaurate, dibutyltin dilaurate, dibutyltin sulfide, stannous octoate,lead octoate, ferric acetylacetonate, bismuth carboxylates,triethylenediamine, N-methyl morpholine, like compounds and mixturesthereof. An amount of catalyst is advantageously employed such that arelatively rapid cure to a tack-free state is obtained. If anorganometallic catalyst is employed, such a cure can be obtained usingfrom about 0.01 to about 0.5 parts per 100 parts of thepolyurethane-forming composition, by weight. If a tertiary aminecatalyst is employed, the catalyst preferably provides a suitable cureusing from about 0.01 to about 3 parts of tertiary amine catalyst per100 parts of the polyurethane-forming composition, by weight. Both anamine type catalyst and an organometallic catalyst can be employed incombination.

The present invention includes a filler material. The filler materialincludes fly ash. The filler can be exclusively fly ash, or it canoptionally include conventional fillers such as milled glass, calciumcarbonate, ATH, talc, bentonite, antimony trioxide, kaolin, or otherknown fillers. Preferably, fly ash makes up at least 50 percent by totalweight of the filler used in the present invention. More preferably, flyash makes up at least 75 percent of the filler, and even more preferablyat least 90 percent of the filler used in the present invention. Mostpreferably fly ash makes up substantially all of the filler material,i.e. at least 99 percent of the filler is fly ash.

Fly ash is a residue that results from the combustion of pulverizedcoal, and can include various proportions of oxides of silicon (Si),aluminum (Al), iron (Fe), calcium (Ca), and magnesium (Mg). The majorportion of fly ash is composed of oxides of aluminum and silicon. Flyash can be classified as either Class C or Class F type fly ash. Class Cfly ash is obtained from subbituminous and lignite coals. Class F flyash is obtained from bituminous and anthracite coals. The fly ash of thepresent invention is Class F fly ash. The fly ash used in the presentinvention can be treated according to known processes to removeimpurities or undesirable components. For example, fly ash can betreated by water washing. Alternatively, fly ash can be treated bydirect acid leaching (DAL) as described in CS-4765. As anotheralternative, fly ash suitable for use with the present invention can bepurchased commercially.

Fly ash can be included in a formulation of the present invention at ahigher loading than can be obtained using conventional fillers. Fly ashcan be loaded at greater than 400 parts of fly ash per 100 parts ofactive hydrogen compounds. Conventional fillers loaded at greater than400 parts per 100 parts can cause problems in a process for preparing apolyurethane carpet backing. For example, conventional fillers can causean unacceptable viscosity increase in a polyurethane-forming formulationwhen included at a concentration of greater than 400 parts. For thepurposes of the present invention, filler can be loaded into a precoator laminate coat at a concentration of from about 100 to about 1000parts of filler per 100 parts of active hydrogen containing compounds.Preferably the filler is loaded at a concentration of from about 300 toabout 900 parts per 100 parts. More preferably the filler is loaded at aconcentration of from about 300 to about 700 parts per 100 parts ofactive hydrogen containing compounds. In a foam coat, filler can beloaded at a concentration of from about 100 to about 400 parts of fillerper 100 parts of active hydrogen containing compounds. Preferably,filler is loaded at from about 150 to 400 parts, more preferably fromabout 200 to about 400 parts.

The present invention also includes a filler wetting agent. A fillerwetting agent generally performs the function of compatiblizing thefiller and the polyurethane-forming composition. Useful filler wettingagents can include ethoxylated phosphate esters in an organic carrier.Examples of suitable filler wetting agents include Maphos™ 56, Pegafax™410, and Code 5027 (available from Fibro Chem, Inc.). Other usefulfiller wetting agents could include sodium lauryl sulfate,oleoylsarcosine, cocoamide, and triisopropanolamine stearate.

A filler wetting agent can be included in a polyurethane-formingcomposition of the present invention at a concentration of at leastabout 0.5 parts per 100 parts of filler, by weight. Preferably thefiller wetting agent is included at a concentration of from about 0.5 toabout 1.5 parts per 100 parts of filler, more preferably from about 0.75to about 1.25 parts per 100 parts of filler.

The present invention can include other optional components. Forexample, a polyurethane-forming composition of the present invention caninclude a surfactant, a blowing agent, a flame retardant, pigments,antistatic agents, reinforcing fibers, antioxidants, preservatives,water scavengers, acid scavengers, and the like. Examples of suitableblowing agents include gases such as air carbon dioxide, nitrogen,argon, helium, and the like; liquids such as water, volatile halogenatedalkanes such as the various chlorfluoromethanes and chlorfluoroethanes;azo-blowing agents such as azobis(formamide). Preferred in the practiceof this invention is the use of a gas as a blowing agent. Particularlypreferable is the use of air as a blowing agent.

A surfactant can be desirable in the present invention. A surfactant canbe particularly useful in preparing a polyurethane foam coat, or apolyurethane laminate coat using a composition of the present invention.Suitable surfactants include block copolymers of ethylene oxide andsilicone surfactants. For example, suitable block copolymers of ethyleneoxide include copolymers having at least 60 weight percent of thepolymer being derived from oxyethylene units, 15 to 40 weight percent ofthe polymer being derived from polydimethylsiloxane units, and thepolymer having a molecular weight of less than 30,000, as described inU.S. Pat. No. 4,483,894. A surfactant can be included in a formulationof the present invention in an amount ranging from about 0.01 to about 2parts per 100 parts by weight of polyol.

Backed carpets can include a precoat and a laminate coat applied to theback of a carpet substrate. In addition, a backed carpet can optionallyinclude an attached foam cushion that is applied to the carpetsubstrate. Generally, carpets having attached cushions are prepared bytufting or weaving yam into a primary backing, applying an adhesiveprecoat to the primary backing to bind the tufted material into thebacking, and then applying a polyurethane foam cushion. Use of any ofthe polyurethane coats can be optional in the practice of the presentinvention. For example, application of a separate polyurethane precoatcan be eliminated by application of a sufficient amount of a laminatecoat, such that the laminate coat soaks into the carpet weave andperforms the function of both a precoat and a laminate coat. Similarly,a polyurethane foam coat can be applied in an amount sufficient toeliminate separate application of a polyurethane precoat and/or laminatecoat.

Use of a precoat layer is preferred because use of a precoat allowsgreater flexibility in the processing conditions used in preparing apolyurethane backed carpet. For example, use of a precoat allows use ofhigher functionality in a polyurethane laminate coat composition. Higherfunctionality tends to have a detrimental effect on the physicalproperties of a carpet. A precoat layer can prevent a subsequentlaminate coat or foam coat from penetrating the carpet weave, therebyenabling use of a laminate or foam coat having higher functionalitywithout detriment to carpet properties.

In preparing polyurethane-backed carpets according to this invention,the individual components of the polyurethane-forming composition aremixed and applied as a layer of preferably uniform thickness onto onesurface of the carpet substrate. It is often preferable to pre-mix allcomponents except the polyisocyanate (and optional blowing agent, when agas is used) to form a formulated “B-side”. This simplifies the meteringand mixing at the time the polyurethane-forming composition is prepared.In preparing a frothed polyurethane backing, it is preferred to mix allcomponents and then blend a gas into the mixture, using equipment suchas an Oakes or Firestone roamer.

The polyurethane-forming composition is then applied to one surface of acarpet substrate before it cures to a tack-free state. Typically thepolyurethane-forming composition is applied to the surface attached to aprimary backing. The composition may be applied to the carpet substratebefore any substantial curing occurs, using equipment such as a doctorknife, air knife, or extruder to apply and gauge the layer.Alternatively, the composition may be formed into a layer on a movingbelt or other suitable apparatus and partially cured, then married tothe carpet substrate using equipment such as a double belt (also knownas double band) laminator or a moving belt with an applied foam cushion.The amount of polyurethane-forming composition used can vary widely,from about 5 to about 500 ounces per square yard, depending on thecharacteristics of the textile. After the layer is applied and gauged,the layer is cured using heat from any suitable heat source such as aninfrared oven, a convection oven, or heating plates. A temperature offrom 100° C. to about 170° C., and a time of from about 1 minute toabout 60 minutes are suitable for curing the polyurethane.

The polyurethane-forming composition of the present invention can beused to coat a variety of substrates. For example the composition of thepresent invention can be used to coat textiles such as: broadloomcarpet; carpet tile; automotive carpet; fabrics for automotive trim;paneling and trunk liners; synthetic playing surfaces; tennis ballcovers; drapery fabrics; wall-covering fabric; woven and non-woven scrimand the like.

EXAMPLES

The following examples and comparative example are meant to beillustrative of the present invention. These examples and comparativeexample are not intended to limit the scope of the claims of the presentinvention and they should not be interpreted in that manner.

Example 1 Precoat

A 2000 molecular weight polyether diol (A) is prepared by reactingdipropylene glycol with propylene oxide to a molecular weight of about1760, followed by reaction with ethylene oxide to a molecular weight ofabout 2000. 85 grams of component A is mixed with 15 grams ofdipropylene glycol, 400 grams of fly ash (AlSil™, JTM grade O1TR), and 4grams of Code 5027 filler wetting agent. A 23 weight percent isocyanateprepolymer (B) is prepared by reacting a dipropylene/tripropylene glycolmixture (45/55 weight percent) with an equal weight of diphenylmethane4,4′-diisocyanate. A 27.5 weight percent isocyanate prepolymer (B′)mixture is prepared by adding a 2.3 functional polyisocyanate tocomponent B. 59.5 grams of component B′ and 0.15 grams of dibutyltinsulfide is added to component A and the components thoroughly mixed. Theresulting precoat blend is applied to a commercial grade loop nyloncarpet having a woven polypropylene primary backing (Sea Island) with ablade over roll applicator (i.e. doctored) at a rate of 30 ounces persquare yard (opsy). The carpet is cured for eight (8) minutes in an ovenmaintained at 120° C. A mechanical froth as described in U.S. Pat. No.5,104,693 is doctored onto the precoated carpet. A non-woven polyesterscrim, as described in U.S. Pat. No. 4,853,280 (Style NO. 2117 fromHoechst Fiber), is placed onto the surface of the uncured froth. Theresulting composite is cured for an additional eight (8) minutes at 120°C. The carpet backing is tested for Edge Curl, Edge Ravel, and Tuft Bindas described below. The results of the testing are recorded in Table 1.

Tuft Bind

Tuft Bind is determined according to ASTM D-1335.

Edge Curl

Submerge three 2″×6″ pieces of carpet in room temperature water for 30seconds. Wring the excess water from the carpet. Place the samples on aflat surface with the backing side down. Weight down the samples at thefirst 2″ of the end opposite the end to be measured. Set a timer for 30minutes and leave the samples undisturbed for the duration of the timersetting. After 30 minutes measure the distance from the flat surface tothe backing side of the outer edges of each piece.

Edge Ravel

The Edge Ravel test is conducted using an Instron. Die cut three 2″×6″carpet samples (1 each from left, right and center of carpet, cut leftand right samples no closer than 1″ from the edge of the carpet).Condition the samples for at least 24 hours at 23° C. ±3° C., 50%humidity, ±5%. Prepare the samples by pulling out two complete tuftrows. This can be accomplished using needle nose pliers. Trim any excessprimary backing, foam, or scrim away from the third tuft row withscissors. Start pulling the next tuft row approximately 1.5 to 2 inchesof total yarn length along the prepared length. Mount the tension loadcell (set at either 100 or 10 lbs.) and allow the cell to warm up for 10minutes. Install the pneumatic jaws on the Instron. Check the crossheadlevers to insure that they are in their proper positions. The rightlever should be pushed to the rear and the left lever should be pulledtoward the front of the machine. Operate the Instron according to themanufacturer's instructions, setting the maximum extension at a settingof 8 and the speed at a setting of 10. Place the test specimen in thelower jaw of the Instron with the prepared edge facing upwards. Securethe partially unraveled tuft row in the upper jaw. Start the test bypressing the UP button on the control panel. Record the results.

Example 2 Comparative Precoat Example

The procedure of Example 1 is followed, except 215 parts of ATH is usedinstead of fly ash, and 1.5 parts of Code 5027 filler wetting agent isused instead of 4 parts. The carpet was tested for edge curl, edgeravel, and tuft bind. The results are recorded in Table 1.

Example 3 Laminate Coat Prepared With Scrim

The precoat blend of Example 1 is used with the following exceptions:65.0 parts of component B′ per 100 parts of polyol are included; ablowing agent (water, 0.5 parts per 100 parts of polyol) is included;and, a surfactant (Niax™ L-5614, 0.75 parts per 100 parts of polyol) isincluded. The formulation is mechanically frothed to a density of 1200g/ml, and the froth is applied to Sea Island at a rate of 49 opsy. Anon-woven polyester scrim, as described in U.S. Pat. No. 4,853,280(Style NO. 2117 from Hoechst Fiber), is placed onto the surface of theuncured froth. The carpet composite is cured in an oven for 3.5 minutesat 120° C. The scrim is flattened onto the laminate with a smooth roller(regauged) according to a procedure described in U.S. Pat. No.4,278,482. The carpet sample is cured for an additional 4.0 minutes at120° C. The laminate is tested for tuft bind, edge ravel and edge curl.The results are reported in Table 1.

Example 4 Laminate Prepared With a Scrim

A laminate coat is applied to the same carpet substrate according to theprocedure of Example 3. The laminate blend is prepared as in Example 3except diethylene glycol chain extender is used instead of dipropyleneglycol. The results are recorded in Table 1.

TABLE 1 EXAMPLE NO. 1 2^(A) 3 4 Carpet Style Sea Island Sea Island SeaIsland Sea Island Tuft Bind (lbs) 11.5/10.9 13.3/10.7 11 14 Edge Ravel(lbs) 2.0/3.7 2.1/2.1 0.8 1.8 Edge curl (cm) 0/0 0/0 0.01 0.02 ^(A)Notan example of the present invention.

Example 5 Foam Coat

A foam coat is prepared using 90 parts of a polyol (Voranol® 9741), 10parts of diethylene glycol chain extender per 100 parts of polyol, 220parts of fly ash filler (AlSil, JTM grade O1TR) per 100 parts of polyol,Code 5027 filler wetting agent (0.5 part per 100 parts of filler),Isonate® 7045 isocyanate (41.5 parts per 100 parts of polyol) dibutyltinsulfide catalyst (0.15 parts per 100 parts of polyol), and Niax L-5614surfactant (0.75 parts per 100 parts of polyol).

Example 6 Viscosity of Compounds Containing Fly Ash Filler

The compound viscosity data are obtained using the following procedure.A stock polyol blend is prepared with 85 parts per hundred parts ofVoranol® 9120 polyol, 15 parts per hundred parts of dipropylene glycolchain extender, and 1 part per hundred parts of water. A filler wettingagent and a filler are added to the polyol in varying amounts (see Table2). The components are mixed to 120° F., then cooled to 72° F. Theviscosity of the mixtures are determined using a #7 spindle rotating at10 rpm on a Brookfield viscometer model RVTDV-II. The results arerecorded in Table 2.

TABLE 2 Filler ATH (H36U)^(a) CaCO₃ (D70)^(a) AlSil (OlTR) Loading 200300 200 300 200 300 400 400 400 Temperature 72 72 72 72 72 72 72 82 92(° F.) Viscosity 7200 19600 7600 30800 3600 10400 22400 14000 11600(cps) ^(a)Not an example of the present invention.

What is claimed is:
 1. A polyurethane-forming composition useful forpreparing a polyurethane precoat, polyurethane laminate coat, orpolyurethane foam coat comprising: (a) a polyol; (b) a chain extender;(c) a polyisocyanate; (d) a catalyst; (e) a filler wetting agent; and(f) a filler, wherein the filler includes Class F fly ash.
 2. Thepolyurethane-forming composition of claim 1 wherein the compositionadditionally includes: (1) a surfactant; and (2) a blowing agent.
 3. Thepolyurethane-forming composition of claim 1 wherein the polyol has anaverage functionality of from about 1.4 to about 3.0.
 4. Thepolyurethane-forming composition of claim 1 wherein the polyol has anaverage functionality of from about 1.6 to about 2.8.
 5. Thepolyurethane-forming composition of claim 1 wherein the polyol is amixture of two or more polyols.
 6. The polyurethane-forming compositionof claim 5 wherein the polyol mixture has an average functionality offrom about 1.97 to about 2.5.
 7. The polyurethane-forming composition ofclaim 5 wherein the polyol mixture has an average functionality of fromabout 1.98 to about 2.4.
 8. The polyurethane-forming composition ofclaim 5 wherein the polyol mixture has an average functionality of fromabout 1.99 to about 2.3.
 9. The polyurethane-forming composition ofclaim 1 wherein the filler includes at least 50 percent Class F fly ash,by weight of total filler.
 10. The polyurethane-forming composition ofclaim 1 wherein the filler includes at least 75 percent Class F fly ash,by weight of total filler.
 11. The polyurethane-forming composition ofclaim 1 wherein the filler includes at least 90 percent Class F fly ash,by weight of total filler.
 12. The polyurethane-forming composition ofclaim 1 wherein substantially all of the filler is Class F fly ash. 13.The polyurethane-forming composition of claim 1 wherein the fillerwetting agent is selected from the group consisting of sodium laurylsulfate, oleoylsarconsine, cocoamide and triisopropanolamine stearate.14. A backed carpet having a polyurethane backing that includes at leastone coat of polyurethane that is prepared from a polyurethane-formingcomposition comprising: (a) a polyol; (b) a chain extender; (c) apolyisocyanate; (d) a catalyst; (e) a filler wetting agent; and (f) afiller, wherein the filler includes Class F fly ash.
 15. The backedcarpet of claim 14 wherein the polyurethane-forming compositionadditionally includes: (1) a surfactant; and (2) a blowing agent. 16.The backed carpet of claim 14 wherein the carpet backing includes: (a) apolyurethane precoat; and (b) a polyurethane laminate coat.
 17. Thebacked carpet of claim 16 wherein the precoat and laminate coat eachincludes Class F fly ash.
 18. The backed carpet of claim 16 wherein thecarpet backing additionally includes a polyurethane foam coat.
 19. Thebacked carpet of claim 18 wherein the precoat, laminate coat and foamcoat each includes Class F fly ash.
 20. The backed carpet of claim 14wherein the carpet backing includes a polyurethane precoat and apolyurethane foam coat.
 21. The backed carpet of claim 20 wherein thefoam coat includes Class F fly ash.
 22. The backed carpet of claim 20wherein the precoat and the foam coat each includes Class F fly ash. 23.The backed carpet of claim 14 wherein the filler wetting agent isselected from the group consisting of sodium lauryl sulfate,oleoylsarconsine, cocoamide and triisopropanolamine stearate.
 24. Apolyurethane-forming composition useful for preparing a polyurethaneprecoat, polyurethane laminate coat, or polyurethane foam coatcomprising: (a) a polyol; (b) a chain extender; (c) a polyisocyanate;(d) a catalyst; and (e) a filler, wherein the filler includes Class Ffly ash.
 25. A backed carpet having a polyurethane backing that includesat least one coat of polyurethane that is prepared from apolyurethane-forming composition of claim
 24. 26. The backed carpet ofclaim 25 wherein the precoat and laminate coat each includes Class F flyash.
 27. The backed carpet of claim 25 wherein the precoat, laminatecoat and foam coat each includes Class F fly ash.
 28. A backed carpethaving a backing comprised of polyurethane and a filler wherein thefiller is comprised of Class F fly ash.
 29. The backed carpet of claim28 wherein the backed carpet includes a precoat and laminate coat. 30.The backed carpet of claim 29 wherein the precoat and/or the laminatecoat comprises polyurethane and Class F fly ash.
 31. The backed carpetof claim 28 wherein the filler includes at least 90 percent Class F flyash, by weight of total filler.
 32. The backed carpet of claim 31wherein substantially all of the filler is Class F fly ash.